Gear mesh analysis usually involves calculations of gear geometry and mesh parameters at chosen mesh positions. Normally, this is done by solving simultaneous equations describing the processes of gear machining and meshing. Numerical methods usually are used only at the stage of analysis (1), (2). As there are practically no restrictions on modern computers memory, a wider use of a numerical approach is feasible when solving gearing problems. A method is proposed to perform gearing analysis in the following way: the initial information about meshing gears is given not analytically, but via co-ordinates of large number of points on gear teeth surfaces. These can be received either via analytical simulation of a manufacturing process (teeth cutting) or via direct CMM measurements of gears. The coordinates could also be retrieved from a different gear mesh simulation software, thus initial teeth shape data would take into account changes occurring due to meshing under load (e.g., different types of deformations, including wear, temperature deformation etc.). A contact between teeth at several meshing positions is modeled via a direct simulation of 'bringing two contacting surfaces together'. The described approach allows universal programs for gear mesh analysis to be created. Models of this type work and remain stable for a wide range of input parameters. They are not sensitive to such phenomena like undercutting and edge contact. These models can be used for gear quality control via CMM measurements, for mathematical modeling of the processes of gear cutting, gear meshing and gear wear. They can be adapted for various types of gears (spur, helical, worm, globoidal, spiroidal etc.). Models created via described approach are discussed. They have been verified experimentally on test rigs and in industry.
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